Web defect scanning apparatus with incandescent illumination means

ABSTRACT

In a scanning apparatus, a scanned transverse region of a moving web is illuminated by focused illumination from an elongate incandescent lamp with a long filament maintained in tension and supported only at its ends to prevent shadows or other luminance variations along the length of the lamp.

CROSS REFERENCE TO RELATED APPLICATIONS

Reference is made to commonly owned U.S. patent application No. 289,875 entitled LAMP FOR SCANNING APPARATUS, filed in the name of Jon Frederick Gehret, and to commonly owned U.S. patent application No. 289,873 entitled CONTROL MEANS FOR WEB SCANNING APPARATUS, filed in the name of Leon Robert Zoeller, both filed concurrently with the present application.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to optical scanners and more particularly to means for illuminating a scanned transverse region of a moving web or the like.

2. Description Relative to the Prior Art

It is well known in the prior art to detect the presence of defects, splices or other irregularities or discontinuities in a moving web by illuminating a transverse region of the web and scanning a region within the illuminated region. Such scanning may be performed by an electronic camera employing either a linear array of photodetectors that view corresponding areas of the illuminated region and that are read out serially, or by means of a single photodetector combined with an optical system that sweeps the viewing area of that detector along the illuminated region.

To detect relatively small or subtle irregularities in a rapidly moving web, the illumination must be of relatively high intensity. For example, U.S. Pat. No. 4,752,897, issued on June 21, 1988 in the names of Leon Zoeller et al. discloses such an apparatus capable of scanning a web at extremely high speeds, requiring handling of the resulting digital signals at data rates of the order of tens of megabytes per second. This rquires quite brilliant illumination because of the extremely short duration during which each individual area of the web or the like is accessed. Correlatively, the illumination must be uniform across the width of the web so that variations in the intensity of the light received by the photodetector are attributable to variations in the web and not to variations in its illumination.

One previously known way to provide the required intense illumination of the web is by means of a laser light source that sweeps a beam of light across the web in synchronism with the detector means. Such a device, however, is inherently expensive. Also, this approach may be limited in its applications because of the coherent monochromatic nature of the light itself, which makes it unsuitable for detecting particular types of defects.

Another known way to illuminate the web is by means of an elongate fluorescent lamp tube located close to the web. Because the entire transverse scanning region of the web is constantly illuminated, as opposed to only a small illuminated area swept along that region, more time is available for each detector element of a linear array type detector to monitor the corresponding scanning area and the light intensity can be correspondingly lower. However, even this lower intensity requirement may not be achievable with a fluorescent tube because such a tube has no localized high intensity light source that can be focused onto the web. In other words, such a tube provides a large area source of relatively low intensity illumination which cannot be intensified by optical means.

U.S. Pat. No. 3,739,219, issued on June 12, 1973, discloses an elongate incandescent light tube intended to replace a plurality of conventional incandescent lamp bulbs to produce an elongate zone of illumination of substantially uniform intensity through which multiple channel punched cards or punched tape pass. One or more elongate filaments are tensioned within the transparent lamp tube by conductive leaf spring members extending into tubular legs extending laterally from the tube at opposite ends thereof. There is no suggestion in this disclosure that the illumination need be of high intensity and it is obvious from FIG. 6 of that patent that this is not a requirement in view of the relatively long distance between the lamp and the photodetector and the absence of any means for focusing light from the lamp filament onto the photodetectors.

U.S. Pat. No. 1,041,100, issued on Oct. 15, 1912, discloses an elongate incandescent lamp with one or more filaments stretched between conductive coil tension springs. The lamp is indicated as being of the type "adapted to be employed with a cylindrical reflector for certain decorative or other purposes of illumination," but there is no suggestion of means for imaging the filament at a remote location or for using the lamp in a web scanning device or the like. U.S. Pat. No. 1,104,807, issued on July 28, 1914, discloses a similar lamp, with no specific indication of its intended use and no reference to reflectors or other light directing means. In this disclosure, one or more filaments are likewise stretched between two conductive tension coil springs, but shunts are placed around the coil springs so that the latter are not required to conduct all of the filament current. In both of these references, at least one end of the filament or multiple filament assemblage is supported by the corresponding tension spring, which causes any fabrication inaccuracy or thermal distortion of the spring to affect the critical filament location.

SUMMARY OF THE INVENTION

In accordance with the present invention, a web moving past a defect scanning device is illuminated transversely by relatively intense focused illumination from an elongate incandescent lamp having a long filament maintained in tension and supported only at its ends to prevent shadows or other illumination variations along the length of the lamp.

Various means for practicing the invention and other advantages and novel features thereof will be apparent from the following description of illustrative embodiments of the invention, reference being made to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic perspective illustration of a web defect scanning apparatus according to a preferred illustrative embodiment of the invention;

FIG. 2 is a fragmentary elevational view of the elongate incandescent lamp employed in the apparatus depicted in FIG. 1;

FIG. 3 illustrates a preferred means of focusing illumination from the elongate incandescent lamp onto the web to illuminate a transverse region thereof, employing an elongate reflector of circular cross section in combination with cylindrical lens means;

FIG. 4 depicts an alternative focusing arrangement employing a reflector of elliptical cross section;

FIG. 5 depicts another alternative focusing arrangement employing a reflector of elliptical in combination with cylindrical lens means; and

FIG. 6 is a block diagram of a system for controlling the scanning rate and illumination intensity of the illustrative apparatus as a function of web speed.

DESCRIPTION OF THE ILLUSTRATIVE PREFERRED EMBODIMENTS

In FIG. 1 a web 10 is shown being moved longitudinally while wrapped partially around rollers 12 and 14. One of these two rollers might serve to drive the web, but in any event the surface velocity of either roller is the same as that of the confronting surface of the web so that the linear velocity of the web can be monitored, for example by a tachometer sensing device 16 or by an analogous device such as a tachometer driven by an idler wheel pressed against the web.

An illumination device 17 comprises an elongate incandescent lamp 18 provided with an internally reflective reflector 20 in the form of a slotted cylinder of circular cross section and an elongate cylindrical lens assembly 22. The illumination device 17 is supported adjacent the web 10 in parallel relation thereto so that the lamp illuminates a transverse region 24 of the web, as described below with reference to FIGS. 4, 5 and 6. A scanning region of the illuminated region 24, in turn, is imaged by a conventional lens 26 onto detector face 28 of a linear CCD (charge couple device) camera 30, which includes a row of small and closely spaced individual detector sites represented as dots along dotted line 32. Accordingly, each individual detector site views a corresponding area along the transverse illumination region 24. The camera also includes a clock that controls clocking of the successive signals out of the camera and a signal transmitter that changes the level of the signal and transforms it into a signal that has more noise immunity for transmission, for example via a coaxial cable 34, by which the camera is connected to a receiver device within parallel processing computer 36. As described in the previously identified U.S. Patent Zoeller et al., the signals emanating from the camera and fed to the computer 36 are digitized to provde a continuous flow of first digital signals and the computer 36 includes means which are operative continuously and in parallel upon the first digital signals for reducing the first digital signals into a continuous flow of second digital signals occurring at a reduced rate from the rate of flow of the first digital signals. These second digital signals represent predetermined events in the process, such as critical parameters and defects in a web. Finally, means are also provided in the computer 36 which are responsive to and operative continuously upon the second digital signals for providing outputs representing the analysis of certain effect in the process represented by the events, for example outputs representing statistical quality control information as to the categories, location and even the source of the events (e.g., the defects or imperfections in the web).

The elongate incandescent lamp 18, best depicted in FIG. 2, comprises a long straight cylindrical tube 38 made of transparent glass or quartz and provided near one end with abutment means comprising an internal annular ridge 40 or a corresponding structure comprising annularly disposed internal bumps. The filament assembly, which is fabricated before being installed in the tube, comprises an elongate filament 42 made of tungsten, platinum, nichrome or some other appropriate metal or metal alloy.

At one end, the filament is swaged into a tubular conductive metal support rod 44 provided with three equiangularly disposed protrusions, two of which are shown at numeral 46. At its other end the filament is swaged into a similar longer tubular support and terminal rod 48, which is provided with an annular metal flange 50 of a diameter appropriate to fit slidably within the bore of tube 38. A compression spring 52 surrounds filament support rod 44 and is seated against a support washer 54 that slidably supports rod 44 and which is of a diameter appropriate to allow the washer to slide within the bore of tube 38 and to seat against internal annular ridge 40. At its other end, spring 52 is seated against metal spring engaging member 56, which is swaged or welded to support rod 44. Before the filament assembly is installed in the tube 38, washer 54 is seated against protrusions 46 by spring 52, which is compressed somewhat between washer 54 and member 56. At its outer end, beyond member 56, support rod 44 is electrically connected to a terminal rod 58 by a flexible metallic conductor strap 60.

To assemble the lamp, the support and terminal rod 48 is fed through the bore of tube 18, which at the stage is open at both ends, and the tube is heated and closed around terminal rod 58 to hermetically seal that end of the lamp tube with rod 58 located substantially coaxial with tube 38. As is well known in the art, rods 58 and 48 are preferably made of an alloy having substantially the same coefficient of thermal expansion as that of the transparent lamp tube to allow direct hermetic sealing between those materials, but other known techniques can also be employed to accomplish such sealing, e.g. a soldering technique. After terminal rod 58 is sealed into the tube, sufficient tension is applied to support and terminal rod 48 to further compress spring 52 and thereby move protrusions 46 away from washer 54, which is seated against annular ridge 40. While terminal rod 48 is held in this position, centered in tube 38 by flange 50, the tube is evacuated and the end of the tube surrounding rod 48 is heated so that it can be closed around rod 48 in hermetically sealed relation thereto; whereupon the tube is allowed to cool and the tension on rod 48 is then released to complete the assembly procedure.

When the lamp is energized, the filament elongates because of its thermal expansion but is maintained constantly under tension and thereby prevented from sagging by spring 52 as support rod 44 slides within central hole 62 of washer 54. Because the filament supporting ends of the support rods 44 and 48 are maintained in coaxial relation to tube 38 by washer 54 and flange 50, respectively, thermal distortion of these support rods or of spring 52 does not effect the location of the filament in relation to the tube, and because the compression spring does not support the filament directly, the location of the filament is not dependent on the dimensional accuracy of the spring itself. It should be noted that spring 52 conducts, at most, only a very small portion of the filament current, or no current at all if washer 54 is made of a non-conductive material, e.g. a ceramic material. Also, because of the high conductivity of rod 44 compared to filament 42, relatively little heat is radiated by rod 44 to spring 52, which is shielded from direct radiation from filament 42 by washer 54. By virtue of these features, the filament is initially coaxial with tube 38 and remains so during the operation of the lamp and is supported only by its ends, without the need for auxiliary support means along the length of the filament.

To illuminate the narrow transverse region 24 of the moving web, the lamp 18 is shown in FIG. 3 partially surrounded by a concentric cylindrical reflector 20 of circular cross section provided with an elongate slot 64. This form of reflector reflects back to the filament most of the radiation striking the reflector and thereby improves the efficiency of the lamp by contributing to maintaining the filament at its required temperature. The filament itself is imaged to illuminate the transverse web region 24 by an elongate cylindrical converging lens assembly 22, which is depicted as comprising two plano-concave elements. Instead of comprising a separate element, the cylindrical reflector could comprise a reflective coating provided directly on the outer cylindrical surface of tube 38 except along an elongate region corresponding to slot 64. Alternatively, FIG. 4 shows the lamp partially surrounded by an elongate reflector 66 of elliptical cross section with the lamp filament 42 located along one focal axis of the reflector and with the web located at or near the other focal axis 68; each such axis being defined by the corresponding focal points of the cross sections of the elliptical reflector. Accordingly, the light striking the reflector is focused onto the web area 24. FIG. 5 shows another embodiment in which an elliptical reflector 70 partially surrounds the lamp, with the lamp filament 42 located along the first focal axis and with a cylindrical lens assembly 72 located beyond the second focal axis 74 along slot 76 so that most of the light reaching the lens is converged into the web area 24 and most of the remaining light is reflected back to the filament to help maintain its desired temperature.

In the apparatus disclosed in the foregoing Zoeller et al. U.S. Patent, the web is run at a nominal rate and the clock means employed to clock the successive analog signal out of the camera also serves to lock a phase-lock loop that produces synchronizing signals at the line rate. These line-rate signals are transmitted to the web encoder interface and may be used to make adjustments to the nominal speed to maintain equal spacing of the scan regions, i.e. the successive regions scanned by the camera, which are narrower than the illumination area 24.

Im many applications, the speed of a web being inspected is not constant, but changes over a wide range because of the operation being performed on the web. Although it would be possible to modify the above described apparatus to maintain the scan regions equally spaced under such circumstances, e.g. changing the scanner clock rate and thereby controlling the web-drive device over a wide range of speeds, this approach is undesirable because of the mechanical inertia in the drive system and the difficulty in achieving accurate speed control of the drive means. Accordingly, the arrangement shown in FIG. 1 employs tachometer 16 to measure the web velocity, as established by the drive motor and other influences, and to control the scanning rate accordingly, so that the scan regions are equally spaced to provide the same amount of information from the camera as the web moves a predetermined distance, regardless of the web speed. As shown in FIGS. 1 and 6, this is accomplished by feeding velocity output signals from tachometer 16 through wires 78 to synchronizing unit 80, which converts the tachometer output signal to a form and frequency range compatible with the signals from scanning clock 82 (FIG. 6) within camera 30. The synchronizing unit is connected to the camera clock 82 by cable 84 and controls the clocking rate of that clock as a function of the web speed, for example, by means of a phase lock loop within the synchronizing unit that changes the clock rate to keep the clock signals in synchronism with the converted tachometer signals. Consequently, rather than having the clock rate determine the web velocity, the web-velocity determines the clock rate so that the scan regions are equally spaced. The resulting camera output signal is fed to a signal transmitter included in the camera, as explained in the Zoeller et al. patent in connection with FIG. 3, thereof, and is then transmitted to a receiver in computer 36 and further processed as taught by the patent.

If the web speed is adjusted only slightly from a nominal speed, as proposed in the Zoeller et al. patent discussed above, the variation in the amount of illumination received by each detector site of the camera during each scan of web areas of equal reflectance is proportionally small and can probably be disregarded. However, if the web speed is changed significantly while maintaining constant scan region spacing, this difference becomes proportionately significant. For example, if the web slows down, each scan region is illuminated for a longer time during each scan interval and, because the detectors integrate the total amount of light received during each scanning cycle, the resulting increased output of the detectors cannot be distinguished from increased output attributable to increased reflectivity of the web. Also, the camera and its associated circuitry are typically designed for maximum sensitivity within a particular luminance range. Accordingly, tachometer 16 also provides web speed signals to illumination control device 86 through wires 88, whereby device 86 adjust the current flow to lamp 18 through wires 90 so that the total amount of light received by the camera detectors during each scan cycle of a web of constant reflectivity is likewise substantially constant, regardless of the velocity of the web. A microprocessor or the like may be incorporated in or associated with illumination control device 86 to adjust the energization of the lamp, not only as a function of web speed but also as a previously determined function of the spectral characteristics of the lamp itself under different energization conditions. For example, if the camera is selectively sensitive to light toward the red end of the spectrum, an increase in voltage to the lamp required by a higher web speed take into account the shift of the lamp spectrum toward the violet range as its filament temperature increases, which can be represented by an appropriate algorithm or look up table in the microprocessor.

The invention has been described with reference to illustrative preferred embodiments but variations and modifications are possible within the spirit and scope of the invention as defined by the following claims. 

I claim:
 1. In an apparatus for scanning a transverse region of a moving web, said apparatus comprising:(a) driving means for moving said web along a predetermined path; (b) scanning means for scanning said web within a predetermined scanning region transverse to said web and said path; and (c) illumination means for illuminating said web within said scanning region; the improvement in said illumination means comprising: (d) an elongate incandescent lamp located adjacent said scanning region, said lamp including an elongate light producing filament supported only at its ends and resiliently tensioned to maintain said filament in straight parallel condition in generally parallel relation to said scanning region; and (e) optical means having a focal point axis coincident with said filament for directing light from said filament to said scanning region.
 2. The invention defined by claim 1 in which said optical means includes;(a) an elongate internally reflective cylindrical reflector of circular cross section coaxial with said filament and provided with an elongate opening, and (b) an elongate cylindrical lens adjacent said opening for focusing toward said scanning region light reaching said lens from said filament through said opening.
 3. The invention defined by claim 1 in which said optical means includes an elongate internally reflective reflector of elliptical cross section open along the side thereof confronting said web, said reflector being located with the first reflector axis defined by the first focal points of the reflector cross sections coaxial with said filament and with the second reflector axis defined by the second focal points of the reflective cross sections located at or near said web within said scanning region.
 4. The invention defined by claim 1 in which said optical means includes;(a) an elongate internally reflective reflector of elliptical cross section, said filament being located coaxially with the first reflector axis defined by the first focal points of the cross section of said reflector, (b) means defining an elongate opening confronting said scanning region along the edge of said reflector opposite said first reflector axis, and (c) an elongate cylindrical lens located adjacent said opening for focusing toward said scanning region light reaching said lens from said filament through said opening, said lens being located between said scanning region and the second reflective axis defined by the second focal points of the cross sections of said reflector. 